Potterton Performa 30 HE Installation & Service Instructions Manual Download

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CONTROLS

To comply with the Building Regulations, each section must have a tick in one or other of the boxes

TIME & TEMPERATURE CONTROL TO HEATING

ROOM T/STAT & PROGRAMMER/TIMER

PROGRAMMABLE ROOMSTAT

TIME & TEMPERATURE CONTROL TO HOT WATER

CYLINDER T/STAT & PROGRAMMER/TIMER

COMBI BOILER

HEATING ZONE VALVES

FITTED

NOT REQUIRED

HOT WATER ZONE VALVES

FITTED

NOT REQUIRED

THERMOSTATIC RADIATOR VALVES

FITTED

AUTOMATIC BYPASS TO SYSTEM

FITTED

NOT REQUIRED

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS?

THE SYSTEM CLEANER USED

THE INHIBITOR USED

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

GAS RATE

/hr

BURNER OPERATING PRESSURE (IF APPLICABLE)

mbar

CENTRAL HEATING FLOW TEMPERATURE

°C

CENTRAL HEATING RETURN TEMPERATURE

°C

FOR COMBINATION BOILERS ONLY

HAS A WATER SCALE REDUCER BEEN FITTED? YES NO

WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE

/hr

MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE)

mbar

COLD WATER INLET TEMPERATURE

°C

HOT WATER OUTLET TEMPERATURE

°C

WATER FLOW RATE

lts/min

FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH
THE MANUFACTURER’S INSTRUCTIONS?

YES

FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING

THE HEATING AND HOT WATER SYSTEM COMPLIES
WITH CURRENT BUILDING REGULATIONS

THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED
IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS

IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO

RATIO READING?

N/A

YES

CO/CO

RATIO

THE OPERATION OF THE APPLIANCE AND SYSTEM
CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER

THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER

/hr

COMMISSIONING ENG’S NAME

CORGI ID No.

SIGN

DATE

BOILER SERIAL No.

NOTIFICATION No.

BENCHMARK No.

GAS BOILER COMMISSIONING CHECKLIST

C O L L E C T I V E M A R K

N/A

5 1 1 1 8 1 5

Summary of Contents for Performa 30 HE

Page 1: ... Baxi Heating UK Ltd 2007 Installation Service Instructions Performa 30 HE These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping ...

Page 2: ...ly relates to dwellings Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations Legislation 4 1 0 Introduction 6 2 0 General Layout 7 3 0 Appliance Operation 8 4 0 Technical Data 9 5 0 Dimensions and Fixings 10 6 0 Sys...

Page 3: ...rty You must ensure that the notification number issued by CORGI is written onto the Benchmark Checklist Scheme Members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days If you notify via CORGI Scheme CORGI will then notify the relevant Local Authority Building Control Scheme on member s behalf Complete the Benchmark Checklist Install and Commission this appliance t...

Page 4: ... Gas Installations The following BS standards give valuable additional information BS 5546 Installation of hot water supplies for domestic purposes BS 5449 Forced circulation hot water systems BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems The boiler meets the requirements of Statutory Instrument T...

Page 5: ...s clear and unobstructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep your back straight bend your knees Don t twist move your feet avoid bending forwards and sideways and keep the load as close to your body as possible Where possible transport the boiler using a sack ...

Page 6: ... serial number and Gas Council number and is situated on the control box It is visible when the case front panel is removed Fig 1 6 The boiler is intended to be installed in residential commercial light industrial E M C environments on a governed meter supply only 7 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit part no 5111073 8 All sy...

Page 7: ...econdary Heat Exchanger 21 On Off Reset Selector Switch 22 Central Heating Temperature Control 23 Hot Water Temperature Control 24 Flame Failure or Blocked Condensate Drain 25 Safety Thermostat Activated Boiler or Flue 26 Fault on Fan or Flue 27 Fault on Pump or Low System Pressure 28 Fault on Hot Water Sensor 29 Fault on Central Heating Sensor 30 Power On 31 Domestic Hot Water Mode 32 Central Hea...

Page 8: ...the boiler is isolated The boiler will not operate and the integral timer if fitted will require resetting once the selector switch is set to either Position i or Position ii 3 3 Frost Protection Mode 1 The frost protection mode is integral to the appliance and functions only with the selector switch see Section 2 1 in the domestic hot water and central heating position If the system temperature f...

Page 9: ...ent 1 2 of Boiler unpressurised Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Cold Water Mains Inlet 15mm DHW Flow 15mm Pressure Relief Discharge 15mm Temperatures C H Flow Temp adjustable 35 C to 85 C max 5 C D H W Flow Temp adjustable 35 C to 65 C max 5 C dependent upon flow rate Heat Input CH Max Min kW 30 5 11 9 Heat Output CH Non Condensing Max...

Page 10: ...0mm D 116mm Ø Min E 185mm F 190mm G 131mm 360 Orientation Tube Ø 100mm D C B A E G F Domestic Hot Water Outlet 15mm Cold Water Inlet 15mm Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 65 mm 65 mm 65 mm 65 mm 65 mm Tap Rail 1 5 to 3o 28mm Condensate Drain ...

Page 11: ...ystem components All systems must be thoroughly drained and flushed out Using for example Betz Dearborn Sentinel X300 or X400 or Fernox Superfloc Universal Cleanser They should be used following the flushing agent manufacturer s instructions System additives corrosion inhibitors and flushing agents descalers should comply to BS7593 requirements e g Betz Dearborn Sentinel X100 and Fernox Copal whic...

Page 12: ...oved after use 6 6 Expansion Vessel Central Heating only 1 The appliance expansion vessel is pre charged to 0 5 bar Therefore the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt 1 For IE the current edition of I S 813 Domes...

Page 13: ...lop which may result in damage to fittings and devices on the system 6 The boiler s maximum working mains pressure is 8 bar therefore all pipework connections fittings etc should be suitable for pressures in excess of 8 bar A pressure reducing valve must be fitted for pressures in excess of 8 bar The manufacturer of any outlet fittings such as a shower valve may require a lower maximum pressure Th...

Page 14: ...Domestic Gas Installations and the current ETCI rules 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing 7 2 Clearances Figs 8 9 1 A flat vertical area is required for the installation of the boiler 2 These dimensions include the...

Page 15: ...rear of the gas service cock Fig 10 3 Ensure that the pipework from the meter to the appliance is of adequate size Do not use pipes of a smaller diameter than the boiler gas connection 22mm 7 5 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current I E e Wiring Regulations In IE reference should be made to...

Page 16: ...n an unheated location the entire condensate discharge pipe should be treated as an external run 9 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used 10 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered If soi...

Page 17: ...a boundary may not be less than 300mm in accordance with the diagram below Terminal Position with Minimum Distance Fig 11 mm Aa Directly below an opening air brick opening windows etc 300 Ba Above an opening air brick opening window etc 300 Ca Horizontally to an opening air brick opening window etc 300 D Below gutters soil pipes or drain pipes 25 E Below eaves 25 F Below balconies or car port roof...

Page 18: ...upplied with the standard horizontal flue is not included in any equivalent length calculations 6 The illustrations opposite show examples of maximum equivalent lengths 7 Full details of part numbers and descriptions of all optional flue components and kits can be found in the Baxi Flue Guide 8 Instructions for guidance and fitting are included in each kit where appropriate NOTE Flue length is mea...

Page 19: ...aptor point X to the joint with the flue terminal point Y One 91 5 bend or two 45 bends can be included without reduction of the flue length If further elbows are required the flue length must be reduced by the following amounts 1 metre for each 91 5 elbow 0 5 metre for each 45 elbow 8 2 Twin Vertical Flue Systems 1 Maximum permissible equivalent flue lengths are Vertical Concentric 3m Vertical Tw...

Page 20: ...flue adaptor 5111070 P Wall Liner 5111067 S Flue Terminal Deflector 5111068 Twin Flue System 80mm diameter E Flue extension pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend pair 135 5111086 J Vertical flue boiler adaptor kit 5111079 H Vertical flue adaptor 5111084 W Pipe support pair 80mm 5111081 Vertical Flue Kits K Vertical flue terminal 5111078 L Lead tile 25 45 246141 Lead tile 35 5...

Page 21: ...nking plate to the boiler top panel Discard the plate 2 There are three restrictor plates supplied in the kit One marked 23 and one marked 27 these can be discarded The third restrictor MUST be positioned as shown in the diagrams below 3 Take one of the gaskets supplied in the kit and place on the boiler top panel 4 Align the appropriate restrictor as shown Position the second gasket over the rest...

Page 22: ...he flashing A mastic seal may be necessary From inside the roof adjust the flue to a vertical position and secure to the roof structure with the clamp supplied 8 7 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 685mm from elbow to terminal Fig 13 The maximum permissible equivalent flue length is 3 metres NOTE Each additional 45 of flue bend will account ...

Page 23: ...ble to reduce or increase with the addition of extensions the length of either or both the 60 100 concentric and 60Ø exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length of the concentric flue is 100mm when measured from the edge of the flue elbow IMPORTANT The maximum equivalent length of concentric flue is 1 5 metr...

Page 24: ...nce a concentric length of 1 25 metres was required and the 60Ø exhaust needed to be 1 metres the graph shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths OK Where both lengths have been determined they can be applied to the graph to check that the installation is permissible For example if it was known that ...

Page 25: ...at the concentric assembly and any extensions fall back to the boiler at an angle of 3 and that the external air inlet is to the bottom 8 Use suitable brackets to support the concentric assembly and any extensions and make good inside and outside 9 The 60Ø exhaust can now be fitted Slide the adaptor over the plain end of the 60Ø exhaust Fig 22 and engage the exhaust in the terminal Slide the adapt...

Page 26: ...the extension at 30mm as shown in two positions directly opposite each other Fig 27 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure using two of the screws supplied 21 The remaining screw must be used to secure the adaptor to the concentric terminal 22 When the plume outlet is positioned under a balcony or other projection Fig 28 it must protrude at least 200mm it is ...

Page 27: ...rea 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 116mm 7 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using the fixing screws 8 Using a spirit level ensure that the plate is level before finally tightening the screws 9 Connect the gas and water pipes to the valves on the wa...

Page 28: ...rds to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside discharge point IMPORTANT Make all soldered joints before connecting to the pressure relief valve 10 6 Condensate Drain see section 7 6 1 Connect the conde...

Page 29: ...e the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 35 NOTE The flue elbow is angled at 91 5 degrees to ensure a fall back to the boiler 3 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 36 4 To dimension X add 50mm This dimension to be known as Y IMPORTANT Check all dimensions before cutting Wall...

Page 30: ...nd ease assembly Fig 38 8 Insert the flue through the hole in the wall Fit the elbow to the boiler adaptor ensuring that it is pushed fully in 9 Draw the flue back through the wall and engage it in the elbow It may be necessary to use soap solution or similar to ease assembly of the elbow adaptor and flue Fig 39 10 Make good between the wall and air duct outside the building 11 Fit the flue trim i...

Page 31: ...nal control input cables have sufficient slack to allow the control box to drop down Tighten the cable clamp s on the boiler chassis 9 If the optional integral timer is to be used it should be fitted at this point Refer to the instructions supplied with the timer NOTE An external frost thermostat cannot be used with the integral timer 10 9 Preliminary Electrical Checks 1 Prior to commissioning the...

Page 32: ...th BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 7 Pressurise the system to 1 0 bar then close and disconnect the filling loop 8 Turn the gas supply on and purge according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 9 Test for gas soundness 10 If at any time during commissioning it is required to terminate a particular cycle e g the pump overrun period...

Page 33: ...urn the selector switch to the Cental Heating and Domestic Hot Water position The power On neon will illuminate Fig 51 7 Turn a hot water tap on to give a flow rate of at least 10l min 8 The pressure should be NG 12 1mbar Propane 32 3mbar If not check that the gas supply pressure is correct Natural Gas 20mbar and Propane 37mbar 9 The pressure can be adjusted if required 10 To check and set minimum...

Page 34: ...the appliance and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the...

Page 35: ...so that its securing tabs are clear of the facia Remove the panel Fig 53 6 Remove the screws securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case Fig 54 7 Note the positions of the two sensing tubes on the fan spigot and three wires on the fan motor and remove them Fig 55 8 Slacken the screws on the fan spigot outlet pipe clamps Ease the clamps in...

Page 36: ...ter is diminished it may be necessary to clean the filters 19 Initially check the cold water inlet tap filter 20 Turn the tap off Undo the blanking cap and remove the thread bush Fig 59 21 Extract the filter and rinse thoroughly in clean water Reassemble and check the flow If required clean the manifold filter as described below 22 Undo the filter cartridge from the inlet return manifold 23 Disman...

Page 37: ...the front edge of the left hand baffle upwards disengaging the spring clip Disengage the tab on the baffle from the slot in the fan hood 6 Undo the screws securing the fan hood to the appliance back panel and draw the fan and hood assembly forwards 7 Remove the screws and spring washers securing the fan to the hood 8 Fit the new fan to the hood using the screws and spring washers previously remove...

Page 38: ... four screws securing the combustion box door and remove the door 2 Undo the screws securing the burner to the injector manifold Draw the burner out of the combustion box pulling the electrode grommets from the slots in the combustion box lower panel 3 Disconnect the electrode leads and grommets from the electrodes Completely remove the burner 4 Undo the screws securing the electrodes to the burne...

Page 39: ...nect the lead and grommet from the electrode being replaced Undo the securing screw and withdraw the electrode to the burner 4 Reassemble in reverse order 14 7 Insulation Fig 67 1 Remove the four screws securing the combustion box door and remove the door 2 Slide the side insulation pieces carefully out of their carriers 3 To replace the rear insulation piece it is necessary to remove the heat exc...

Page 40: ...assemble in reverse order and check the burner pressure Section 11 2 14 9 Central Heating Temperature Sensor Fig 69 1 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way 14 10 Safety Thermostat Fig 69 1 Pull the electrical connections off the thermostat 2 Remove the screws ...

Page 41: ...t from the pump body Undo the two screws securing the body to the pipe and manifold and draw the pump forwards 2 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 3 Connect the wiring to the new pump Examine the O ring seals on the return pipe and manifold...

Page 42: ... vessel outlet spigot and remove the locknut and spring washer securing the spigot to the boiler chassis 5 Undo the screws and remove the appliance upper cross member Slide the expansion vessel out of the retaining clips 6 Reassemble in reverse order Fully recommission the appliance and system 14 17 Condensate Trap Fig 77 1 Disconnect the two sensing wires from the trap connections 2 Squeeze toget...

Page 43: ... C B and disconnect them 4 Undo the securing screws and remove the P C B Transfer the control knob drive pins to the new P C B and turn them fully anticlockwise 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 14 20 Selector Switch Fig 80 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo...

Page 44: ...ating pressure differential valve and a domestic hot water pressure differential valve These are connected to a manifold which is joined to the plate heat exchanger DHW Pressure Differential Valve Fig 83 1 Drain the primary circuit 2 Undo the screw securing the microswitch bracket to the valve Fig 82 3 Disconnect the two sensing pipes and slacken the grub screws securing the valve to the diverter ...

Page 45: ... To examine the diaphragm hold the assembly securely and carefully remove the four screws The diaphragm spring will force the two halves of the valve apart 8 Carefully examine the diaphragm and replace it if there is any damage 9 Reassemble in reverse order CH Pressure Microswitch Fig 84 1 Remove the two wires from the Pressure microswitch 2 Undo the screw securing the microswitch bracket to the v...

Page 46: ...nger from the outer drum by easing it forward 7 Reassemble in reverse order of dismantling 14 25 Flue Overheat Thermostat Fig 88 NOTE The flue overheat thermostat includes a reset button Check that the thermostat will not reset before replacing 1 Remove the fan spigot outlet pipe from the fan and elbow 2 Pull the two wires off the terminals on the flue overheat thermostat Unscrew the thermostat fr...

Page 47: ...F2 1 bk bk r r g g g r g r 2 1 2 3 3 4 1 1 2 3 4 5 6 10 9 8 7 6 5 4 3 2 1 2 3 4 4 5 5 6 7 8 9 Central Heating Temperature Sensor Fan Gas Valve Overheat Stat Hydraulic Differential Pressure Switch Domestic Hot Water Flow Priority Pressure Switch Air Pressure Switch Flame Mains Input Fuse Link g y g y b br bk br b bk Sensing Electrode Pump b b b bk b b b br br b b r bk bk br bk br br br Flue Stat 1 ...

Page 48: ...to max Pump runs Air pressure switch proved neon flashing Burner on neon illuminated Burner output modulates until set temperature is reached Spark at ignition electrodes for up to 10 seconds Go to section A neon flashing Go to section B neon flashing Go to section C Go to sections J M neons flashing Go to section D neon flashing Go to section E Replace PCB Turn selector to the reset position If t...

Page 49: ... neon flashing Go to sections I L DHW flow valve senses no flow Primary water diverted to CH system DHW flow switch released off Close DHW tap Burner goes out Diverter valve spindle assembly faulty Pump stops Operation sequence correct neon flashing Turn selector to reset position If regular resetting is required or appliance still does not operate investigation is necessary neon flashing Go to se...

Page 50: ...ble YES B CH system pressure 0 5 to 1 5 bar Re pressurise system 1 NO Primary flow valve diaphragm damaged Replace diaphragm Flow valve rod obstructed 3 YES Check the tap of the automatic air vent is opened Open the automatic air vent 2 NO NO C YES Continuity across flow microswitch and PCB A5 connector terminals 7 8 Replace microswitch 1 NO NO Primary temperature sensor faulty Cold resistance app...

Page 51: ...ace PCB G Check and correct if necessary 1 Ignition electrode and lead 2 Electrode connection 3 Spark gap and position 230V at Main PCB A1 connector across terminals 3 4 Check wiring YES NO Replace gas valve electrical plug igniter assembly YES H YES Check the burner setting pressure of the gas valve see Section 9 2 of Commissioning 1 Voltage at modulating coil of gas valve is Max burner press app...

Page 52: ...ET selector when turned to Reset position Replace ON OFF RESET selector NO Replace PCB YES K Replace safety thermostat YES NO Overheat thermostat operated or faulty i e continuity across thermostat terminals Allow to cool Continuity across thermostat terminals more than 1 5 ohm J If checks in section I are completed successfully blockage of the condensate drain or trap may have occurred L If check...

Page 53: ...or 5112376 59 E66 408 Electrode Lead 248037 63 E66 411 Spark or Sensing Electrode 247384 72 Pump 248042 101 E66 432 3 Way Valve Assy 248061 131 342 571 Temperature Sensor 247394 135 E66 439 Safety Thermostat 248079 140 Gas Valve 5107339 154 PCB 5112380 169 E66 453 Pressure Gauge 248090 327 Igniter Gas Valve Cable 5112385 A Flue Overheat Thermostat 5112395 22 140 44 63 154 72 135 59 41 101 169 131 ...

Page 54: ...E OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATI...

Page 55: ...INEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE INTERVAL RECORD It is recommended that yo...

Page 56: ...Enquiries 08706 049 049 Website www potterton co uk e oe company All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request ...

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